Process utilizing high performance air-cooled combined cycle power plant with dual working fluid bottoming cycle and integrated capacity control

ABSTRACT

A combined cycle power plant system and methods of operation so as to minimize consumption of cooling water utilizes exhaust from a combustion turbine to generate steam for power generation in a steam turbine topping cycle. The exhaust steam from the steam turbine topping cycle is utilized to vaporize an organic working fluid in an organic working fluid bottoming cycle, where vaporized organic working fluid expanded across a turbine generates additional power. Exhaust gas from the organic working fluid bottoming cycle is condensed utilizing an air-cooled heat exchanger. Heat exchange bundles of the air-cooled heat exchanger are preferably arranged horizontally relative to the ground to maximize efficiency. Turbine inlet cooling is employed at the combustion turbine to recapture energy lost in the system. A thermal energy storage tank may be utilized in conjunction with the turbine inlet cooling to supply chilling water to the system.

PRIORITY

This application is a divisional of and claims priority to U.S.Non-Provisional application Ser. No. 13/586,673 entitled, “HIGHPERFORMANCE AIR-COOLED COMBINED CYCLE POWER PLANT WITH DUAL WORKINGFLUID BOTTOMING CYCLE AND INTEGRATED CAPACITY CONTROL,” filed Aug. 17,2012, naming Thomas L. Pierson and Herman Leibowitz as inventors, whichis a non-provisional of and claims priority to U.S. ProvisionalApplication No. 61/624,824, having the same title, filed Apr. 16, 2012,also naming Thomas L. Pierson and Herman Leibowitz as inventors, thedisclosure of each being hereby incorporated by reference in theirentirety

BACKGROUND OF THE INVENTION

The reduction of water consumption and use is emerging as a top priorityfor all types of power plants as a result of water supply constraints inmany regions of the world. Several factors contribute to intensifiedwater scarcity, including increased demands for electricity, increasedwater use in other sectors (for example, agriculture, municipal watersupply, mining, and manufacturing), tightened government regulations,population growth, new development, and weather variation (includingprecipitation and temperature). Constraints on cooling water suppliesimpact plant site and permitting decisions and current plant operations.Furthermore, there is increasing pressure on the industry to eliminateonce-through cooling systems. However, replacing once through systemswith the more common wet cooling towers may reduce the water circulationrate but does not reduce the overall water consumption (i.e., sameamount of water is evaporated in the cooling process).

More specifically, utility scale thermal power plants traditionally haveused water from an evaporative cooling tower to condense the steamcoming from the low temperature exhaust of a condensing steam turbineused in the thermal bottoming cycle. This results in large amounts ofwater evaporated for every MW-Hr of power produced. Moreover, such waterusage is common in many thermal power plants regardless of whether thethermal energy source is from a coal fired power plant, a nuclear powerplant, or a gas turbine, combined cycle power plant. It has beenestimated that the approximate water consumption of each type of powerplant is:

-   -   Combined Cycle=210 gal/MWH    -   Nuclear=820 gal/MWH    -   Coal=760 gal/MWH    -   Biofuel & Concentrated Solar Power=720 gal/MWH

Recently combined cycle plants have been designed to replace thewater-cooled surface condenser and the evaporative cooling tower with alarge air-cooled steam condenser to operate in conjunction with thecondensing steam turbine, Large air-cooled condensers can condense thelow pressure exhaust from the condensing steam turbine directly in theair-cooled steam condenser, It is estimated that approx 70 power plantsin the ILS, have installed some type of air-cooled steam condenser onthe steam bottoming cycle of combined cycle power plants. This use ofair-cooled steam condensers has eliminated the traditional circulatingcooling water loop and the cooling tower, and is an effective way ofeliminating the use of water for cooling in the thermal bottoming cycleof a combined cycle plant. However, various drawbacks to prior artair-cooled steam condensers exist. First, to maximize the power outputfrom the steam turbine, the condensing temperature and pressure of thesteam must be as low as possible. Thus, typically, the condenser isoperated below atmospheric pressure. However, operating the condenserbelow atmospheric pressure can lead to air infiltration which can lowerthe capacity output of the power plant and increase corrosion of powerplant equipment, which increases the maintenance requirements of theboiler feedwater system, In addition, because steam has a comparativelylarge volume at low pressure, the back end sections of the steam turbinemust be sized quite large for the large specific volume required forthis very low pressure steam, thereby adding to the expense andcomplexity of the overall system. As an example, each pound of steamrequires 333 cubic feet at 1 psia (102° F. condensing temperature) or255 cubic feet at 2.2 psia (120° F. condensing temperature) which aretypical operating ranges for an air-cooled condenser. Since the latentheat of vaporization of steam is about 1025 BTU/lb at 120° F., itrequires a volume of (255 cubic feet/lb×lb/1.025 BTU=) 4 cubic feet/BTU.For this reason, the size of the headers, distribution pipes and tubesin an air-cooled condenser must be relatively large to accommodate thevery large volumes of low pressure steam in the system. One result isadded capital cost. Moreover, traditional air-cooled steam condensersare typically very large, A-frame designs with fans forcing ambient airup through the A-frame arranged condenser coils. A-frame systems such asthis are necessary in order to adequately drain the condenser coils ofthe steam condensate due to the very low steam pressures. However, suchA-frame designs impose added fan power requirements and do not representideal fan airflow across the coils, thereby inhibiting the effectivenessof the air-cooled condenser in the efficiency of the overall powersystem.

Another disadvantage of the prior art practice of utilizing air-cooledsteam condensers for the bottoming cycle of combined cycle thermal powerplants is that the output of the air-cooled combined cycle plant will bedegraded more than that of the traditional water-cooled combined cycleplant because the air-cooled condenser rejects its heat to the higherdry bulb temperature rather than the colder wet bulb temperature of awater cooled combined cycle. This degradation occurs at alltemperatures, but especially during the high ambient temperatureperiods. As the ambient temperature rises, the output from the steamturbine will be reduced due the higher backpressure caused by the highercondensing temperatures experienced by the air-cooled condenser,especially during hot periods of the day when the heat from thecondensing steam must be transferred to the ambient air temperature.Also as the ambient temperature increases, the difference between thedry bulb temperature and the coincident wet bulb temperature tends toincrease, thereby causing a corresponding increased reduction in theair-cooled combined cycle plant output versus the output of a watercooled plant. This reduction in both gas turbine and steam turbineoutput occurs generally during the time of peak stress on the electricalgrid—a time when power demand is usually highest due to peak HVAC loads,yet when the ability of the gas turbine generation fleet capacity isusually at its lowest. For the foregoing reasons, power plant designcontinues to strongly favor the more water consumptive wet coolingtowers for combined cycle plants rather than air-cooled condensing.

There is an increasing need for new designs which can minimize waterusage in both existing as well as future new power plants and yetmaintain plant power output, especially during high ambient temperaturepeak periods.

BRIEF SUMMARY OF THE INVENTION

The current invention seeks to greatly reduce or eliminate the need forcooling water in large scale, combined cycle power plants whileeliminating the drawbacks typically associated with air-cooledcondensing bottoming cycles, Moreover, the current invention wouldgreatly reduce or eliminate the variation in combined cycle plantperformance of an air-cooled plant when compared to a water-cooledplant, particularly during periods of high demand and periods during theday or season when ambient temperatures are elevated.

Generally, the system of the invention employs four circuits. A firststeam turbine topping circuit uses water as a first working fluid whichcirculates via a first circuit pump through a heat recovery steamgenerator disposed to receive exhaust from a combustion turbine system.Steam produced from the heat recovery steam generator passes through asteam turbine, then through a steam condenser/ORC vaporizer and back tothe first circuit pump. A second organic fluid bottoming circuit uses anon-water fluid as a second working fluid which circulates via a secondcircuit pump through a steam condenser/ORC vaporizer, then through anORC turbine, then through an air-cooled condenser and back to the secondcircuit pump. The first circuit and the second circuit cooperate orotherwise overlap with one another via the steam condenser/ORCvaporizer. The third circuit is a refrigeration cycle which circulates arefrigerant working fluid from a compressor to a condenser. Thecondenser may be a water cooled condenser or it may be an air-cooledcondenser. The air-cooled condenser may be the same air-cooled condenserutilized in the second circuit or it may be a separate air-cooledcondenser. The refrigerant working fluid will be condensed in thecondenser and the liquid refrigerant will then travel through a pressurereduction device, such as a valve or orifice, after which therefrigerant will circulate through an evaporator where the refrigerantwill be vaporized. Thereafter, the vaporized refrigerant will thencirculate back to the compressor. The fourth circuit is a chilled watercircuit that includes a turbine inlet cooling system disposed to coolinlet air of the combustion turbine system. The chilled water willcirculate from the evaporator of third circuit to cooling coils of theturbine inlet cooling system. The cooling coils are disposed in the airpath of the combustion turbine system. Once chilled water is circulatedthrough the cooling coils, the chilled water is pumped by a fourthcircuit pump back to the evaporator of the third circuit. The thirdcircuit and the forth circuit cooperate or otherwise overlap with oneanother via the evaporator.

Thus, the invention comprises a combined cycle power plant having acombustion turbine with a turbine inlet air cooling system to vary ormaintain air mass flow going through the combustion turbine, a steamturbine topping cycle utilizing the exhaust of the combustion turbine asa heat source for producing steam, a steam turbine, and a steamcondenser for condensing steam exiting the steam turbine. The inventionfurther comprises an organic working fluid bottoming cycle having anexpander to expand a heated vaporized organic working fluid and anair-cooled condenser for condensing the organic working fluid utilizingambient air as the cooling medium. The steam condenser for condensingsteam exiting the steam turbine also functions as an organic fluidvaporizer for the organic fluid bottoming cycle, vaporizing the organicfluid prior to introduction into the expander. Preferably the steamturbine topping cycle utilizes a steam turbine designed for a higherexiting steam temperature and pressure, such as a backpressure steamturbine, rather than the more common condensing steam turbines that arenormally used on combined cycle plants. This new backpressure steamturbine is combined with the separate organic working fluid cycle toeliminate the need for the steam to be condensed in the air-cooledcondenser. For purposes of the invention, the term “organic workingfluid” is used to describe a second working fluid which may be anyworking fluid other than water and which has a vaporization temperaturebelow that of water as described below. Organic working fluid mayinclude, without limitation, ammonia (NH3) or other non-carbon workingfluids.

Rather than condensing steam in the air cooled condenser as common inthe prior art, condensing is now done in a two step process. First, thesteam leaving the steam turbine is condensed in a heat exchanger, suchas a vapor-to-vapor heat exchanger. This heat exchanger may be of anytype, hut is preferably a shell and tube or a plate and frame type heatexchanger known in the art, with steam on one side of the heat exchangerand the organic working fluid on the other side of the heat exchanger.The second part of the condensing process utilizes heat from thecondensing of the steam to vaporize the organic working fluid. Thisheated organic working fluid is then used to drive a separate expanderto produce additional power. Thereafter, the expanded organic workingfluid is condensed in an air-cooled condenser. The specific organicworking fluid is preferably selected to match the heat releaseproperties of the exhaust steam from the backpressure steam turbine. Theseparate working fluid will be designed to boil at a higher pressure anda lower temperature (and a lower specific volume) than will moretraditional water and this separate working fluid will also condense ata lower volume and temperature than would water. A thermal energystorage (TES) tank may preferably be employed for use with the turbineinlet cooling of the combustion turbine.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B illustrate the four separate fluid circuits of theinvention, including a topping steam cycle and a bottoming organic fluidcycle.

FIGS. 2A and 2B illustrate the system of FIGS. 1A and 1B, but includesan optional Thermal Energy Storage (TES) tank, an optional preheater,and an optional condenser spray system,

FIG. 3 illustrates one type of air cooled heat exchanger contemplated bythe invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIGS. 1A and 1B, there is shown a schematic of a.combined cycle power plant 10 of the invention, generally having a.combustion turbine 20, a turbine inlet cooling system 30, a steamturbine topping system 40, an organic fluid bottoming system 50, a steamcondenser/organic vaporizer 60, and an air-cooled organic fluidcondenser 80,

FIGS. 2A and 2B illustrate the same components of power plant 10 asFIGS. 1A and 1B, but includes an optional thermal energy storage system100 and an optional condenser spray system 120, either of which can beused alone with the system of FIGS. 1A and 1B or in combination with oneanother as part of the system of FIGS. 1A and 1B.

In one preferred embodiment, combustion turbine 20 is a natural gasturbine having an air inlet 35 which would contain or be attached to anair cooling coil 32 of the turbine inlet cooling system 30. The aircooling coil 32 utilizes chilled water circulated therethrough to coolthe inlet air to the gas turbine 20. The cooled inlet air would travelthrough the gas turbine 20 and then be exhausted through duct 24 into aheat recovery steam generator (HRSG) 48 with the cooled exhaust airexiting to the ambient air at stack 49. In addition to air cooling coil32, turbine inlet cooling system 30 would preferably, include a chilledwater primary circulating pump, 29 and an chiller system 26. Chillersystem 26 preferably includes an evaporator,

The heat collected by the HRSG 48 would be used in a steam turbinetopping system 40 which would utilize water as a first working fluid 41,and generally includes a steam turbine 42 having a steam inlet 44 andexhaust steam outlet 46; the heat recovery steam generator (HRSG) 48having a first working fluid inlet 53 and a first working fluid outlet52; and the steam condenser/organic vaporizer 60 having a first workingfluid inlet 56, a first working fluid outlet 58, a second working fluidinlet 61 and a second working fluid outlet. 62. Steam turbine 42 may beutilized to drive one or more electric generators 64 in a manner wellknown in the art, A pump 66 may be provided to pump condensed firstworking fluid from the steam condenser/organic vaporizer 60 to the heatrecovery steam generator 48 with first working fluid entering HRSG as aliquid at 53. The heat recovery steam generator 48 is disposed toutilize waste heat in the form of heated exhaust air from the combustionturbine 20 to vaporize the first working fluid with vaporized firstworking fluid leaving HRSG at point 52 and entering steam turbine 42 atpoint 44.

In one preferred embodiment, the steam turbine 42 is a backpressureturbine. Those skilled in the art will appreciate that prior artcombined cycle power plants typically employ condensing steam turbinesbecause such steam turbines produce low pressure exhaust steam at acondensing temperatures slightly above the ambient air temperature whichis used as the heat sink. The present invention would replace the priorart condensing steam turbine with a backpressure steam turbine so as toreduce the cost of the steam turbine and to reduce the volume requiredin the steam condenser 60. This backpressure steam turbine will notresult in as much power generation as the prior art condensing steamturbine because the system of the invention condenses steam at a muchhigher temperature than the traditional steam bottoming cycle. Incertain preferred embodiments, the condensing temperature at condenser60 would be over approximately 150° F. and preferably in a range ofapproximately 180° F. to 250° F. as compared to a prior art condensingtemperature that would be more typically in the range of 100° F. to 130°F., Persons of ordinary skill in the art will appreciate that thecondensing temperature of prior art systems as described herein would hemuch closer to the ambient dry bulb temperature (if the system utilizesair cooling) or the ambient wet bulb temperature (if the system utilizeswatercooling. To regain the lost power from the steam turbine due to thehigh condensing temperature, the heat from condensing this steam wouldhe reused to vaporize the second working fluid and additional powerwould be recovered in a second bottoming system described below.

The heat from the condensing steam is transferred to a second workingfluid 51 which is utilized in the organic fluid bottoming system 50. Thesecond working fluid 51 is an organic which for the purposes of theinvention, is any fluid other than water, and may include, withoutlimitation, ammonia or other non-carbon fluids. The organic fluidbottoming system 50 generally includes an organic working fluid turbine72 having a second working fluid inlet 74 and a second working fluidoutlet 76, which turbine 72 is utilized to drive one or more electricgenerators 78 in a manner well known in the art. The second workingfluid inlet 74 is in fluid communication with the second working fluidoutlet 62 of steam condenser/ORC vaporizer 60 permitting the turbine 72to receive vaporized organic fluid, i.e., the second working fluid 51,from the vaporizer 60.

Air-cooled condenser 80 is disposed at gaseous inlet 84 to receive thevaporized organic working. fluid exhaust from turbine 72 and pass thevaporized organic working fluid through one or more bundle(s) 91 so asto condense the organic working fluid back to a liquid state.Thereafter, the liquid organic working fluid leaves air-cooled condenser80 at liquid outlet 86 and is then circulate through fluid pump 65 whichwould pump second working fluid 51 back to the steam condenser/vaporizer60 where the liquid second working fluid 51 will enter at point 61 forreceipt of heat from the gaseous first working fluid 56, i.e.,condensing steam 56, thereby causing the second working fluid 51 tovaporize and exit the condenser/vaporizer 60 at point 62. The vaporizedsecond working fluid 51 will then pass to the organic working fluidturbine 72 entering at point 74. The second working fluid 51 is thenexpanded in the turbine 72 and exits at point 76 to be re-circulatedback to the air-cooled condenser 80) as described above. It should heapparent to those skilled in the art that the term “organic workingfluid turbine” may also be known as an “expander” or a “turbocxpander”.Moreover, in certain embodiments, bundles 91 are generally comprised ofone or more coils through which the second working fluid flows.

In certain embodiments of the invention, the air-cooled condenser 80utilized in the invention is quite different from the prior artair-cooled steam condensers, Which typically consist of A-Frame steamcondensers well known in the art. The air-cooled condenser of theinvention is designed to condense the organic second working fluid asopposed to condensing steam in the prior art condensers. As such, mostprior art power plant air-cooled condensers utilize a type of A-framedesign with a large steam inlet distribution manifold header disposedabove and connect to two large banks of substantially vertically angledcondenser panels (left and right) arranged so that steam condensateexits each panel at the bottom of the panel and is collected by acondensate header at the bottom of each panel. Multiple large fanslocated near the bottom of the A-frame force air upwards through theangled condenser panels such that the cooling air exits the A-framesystem at an angle to the horizontal (as opposed to vertically relativeto the horizontal).

With reference to FIG. 3, one preferred embodiment for the air-cooledcondenser 80 of the subject invention utilizes one or more heatexchanger coil bundles 91 which would be mounted on a support structure93 with the heat exchanger bundles 91 positioned so as to besubstantially horizontal and parallel to the ground. Moreover, the heatexchanger bundles 91 are suspended above the ground by the supportstructure 93 such that air might be drawn across the bundles 91 frombelow utilizing one or more large, induced draft fans 88 mounted abovethe array of heat exchanger bundles so as to draw air vertically upthrough the horizontally mounted heat exchanger bundles, therebyminimizing air turbulence and maximizing heat transfer therebetween. Incertain embodiments, the fans 88 are preferably spaced apart from theheat exchanger bundles 91 by a distance sufficient to form a plenum 99between the fan(s) 88 and the bundles 91, thereby allowing a single fan88 to draw air through multiple heat exchanger bundles. In certainembodiments, plenum 99 is preferably partially or fully enclosed, Incertain embodiments, one or more fans 88 preferably include a fan ring98 around the fan 88 and extending up above the fin so as to maximizethe distance from the top of the fan ring, where the air exits the aircooled condenser system 80, to the lower portion of the air cooledcondenser system 80 where the air intake is located, thereby minimizingair recirculation.

It will be appreciated that in many prior art systems, condensing steamturbines were utilized for the bottoming cycle of combined cycle powerplants because the exhaust steam from the bottoming cycle could bereadily cooled with water cooled condensers and cooling towers. Water asthe bottoming cycle working fluid has been desirable in the prior artbecause it is stable, inexpensive, safe and efficient. Moreover, it isreadily cooled with water from cooling towers. However, such watercooling towers may be undesirable for various reasons such asenvironmental concerns and/or impractical in certain locations wherewater may not be readily available, such as deserts. In order to utilizea smaller, lower-cost air-cooled condenser as the heat exchanger forcooling in the bottoming cycle, therefore, it is necessary in theinvention to eliminate the direct condensing of the steam working fluidby the ambient air heat exchanger and to replace the lower temperaturesection of a traditional prior art steam turbine bottoming cycle with aseparate closed-loop, organic working fluid bottoming cycle. Thoseskilled in the art will appreciate that such a closed-loop, organicworking fluid bottoming cycle can operate at higher pressures than theprior art. By expelling the exhaust the organic working fluid from theORC turbine at higher pressures, the volume of the exhaust vaporizedorganic working fluid to he condensed is minimized, particularly ascompared to the volume of ambient temperature steam, and as such,renders use of the smaller air-cooled condenser system described hereinas much more practical, In addition, the pressure of this organic fluidcan he easily maintained well above atmospheric pressure even for thelowest temperature condensing temperatures, thereby eliminating theconcerns of air infiltration into the system. For example, if ammonia (R717) were selected as the second working fluid, each pound of ammoniarequires 1.38 cubic feet at 218.6 psia (at 102° F. condensingtemperature) or 1.05 cubic feet at 286.4 psia (at 120° F. condensingtemperature) which would be typical condensing temperatures for anair-cooled condenser. Given that the latent heat of vaporization ofammonia is around 634 btu/lb, each cubic foot of ammonia condensed wouldreject about 604 BTU versus about 4 BTU for each cubic foot of steamcondensed in a prior art system, Therefore an air-cooled condenserutilized. with steam must be designed to process approximately 150 timesthe volume as that of an air cooled condenser utilized with gaseousammonia in order to reject the same amount of heat at the same normalcondensing temperatures (120 F in the above example). One drawback tothe use of air-cooled condensing however is that the power output islower than for traditional water-cooled condensing and this degradationof output is especially severe during the high ambient temperatureperiods of the day and year. To compensate for this, in conjunction withthe dual working fluids of the invention described herein, the inventionemploys turbine inlet cooling at the air inlet of the combustionturbine, thereby regaining the output of the combined cycle plant.Specifically, a turbine inlet cooling system used in conjunction withthe gas turbine will more than compensate for the lower output of thesteam bottoming cycle during high ambient periods.

With this in mind, turbine inlet cooling system 30 is provided with acooling coil 32 having a chilling water inlet 34 and a chilling wateroutlet 36, Cooling coil 32 is generally disposed in the air flow path ofcombustion turbine 20, preferably at the air inlet 35 for combustionturbine 20, such as in a filter house. While the preferred embodimentwill describe turbine inlet cooling utilizing chilled water as thecooling medium in cooling system circuit 31, other types of turbineinlet cooling are contemplated, including without limitation, the use ofother substances, such as refrigerant, in coils 32 or heat transferfluids other than water. In certain preferred embodiments, chillingwater is utilized in turbine inlet cooling system 30. The chilling wateris circulated through an evaporator 26 of a chiller as is known in theart, in order to reduce the temperature of the chilling water.Evaporator 26 generally includes a chilling water inlet 27 and achilling water outlet 28. The chilling water will be cooled in theevaporator 26 by heat transfer with a refrigerant which will absorb heatfrom the chilling water and which will cause the refrigerant to bevaporized, This vaporized refrigerant will then enter a compressor 38driven by a motor or similar device. The compressed refrigerant exitsthe compressor and flows to a condenser which will condense therefrigerant from a vapor to a liquid. The condenser may be a watercooled condenser or an air-cooled condenser. in a manner known in theart, the condensed refrigerant is then passed through a flow controldevice, such as an expansion valve, or similar pressure reduction devicein order to reduce the pressure of the refrigerant, thereby resulting ina temperature reduction of the refrigerant such that when the lowpressure, cooled, liquid refrigerant enters the evaporator 26, therefrigerant can be used to absorb heat from the chilling water, therebycausing the refrigerant to be vaporized, after which the refrigerationcycle repeats.

With reference to FIGS. 2A and 2B, in certain embodiments, to furtherenhance the effectiveness of turbine inlet cooling, the turbine inletcooling system 30 may utilize a thermal energy storage system (TES) 100,which may include components such as a TES tank 102. TES tank 102generally includes a water column 104 disposed therein and having a topheader 106 and a bottom header 108, with one or more first ports 110connected to the top header 106 and one or more second ports 112connected to the bottom header 108. In configurations where a TES tank102 is incorporated as part of the turbine inlet cooling system 30, thechi fling water outlet 36 of coil 32 as well as the inlet 27 ofevaporator 26 is in fluid communication with the top header 106 of TEStank 102 via the one or more first ports 110, while the inlet 34 of coil32 as well as the outlet 28 of evaporator 26 is in fluid communicationwith the bottom header 108 of TES tank 102 via the one or more secondports 112. By including an optional thermal energy storage system 100 inthe power plant 10, the high-ambient power output of the air-cooledpower plant 10 of the invention can actually exceed that of traditionalwater-cooled combined cycle power plants while greatly reducing oreliminating the consumption of fresh water. Moreover, while the use ofair-cooled condensing will result in slightly lower power output ofpower plant 10 during hot periods as compared to the prior artwater-cooled systems, the use of turbine inlet cooling of the combustionturbine, particularly when combined with thermal energy storage, canhelp recapture most or all of this lost power.

In certain embodiments, the air-cooled condenser system 80 utilized tocool the second working fluid 51, may also be utilized, eithersimultaneously, or alternatively, to cool the refrigerant utilized inevaporator 26. In such case, as shown in FIGS. 1A-2B, evaporatorrefrigerant inlet 97 is in fluid communication with air-cooled condenserrefrigerant outlet 96, while evaporator refrigerant outlet 95 is influid communication with air-cooled condenser refrigerant inlet 94. Therefrigerant, designated as working fluid 39, flows through one or morebundles 91 as described above. In one embodiment, as described below,during peak hours when organic fluid bottoming system 50 is in use,air-cooled condenser system 80 is utilized to cool the second workingfluid 51 from organic fluid bottoming system 50. During non-peak hours(such as night time) when organic fluid bottoming system 50 is not inuse, air-cooled condenser system 80 may be utilized to cool refrigerantworking fluid 39 during the process of charging thermal energy storagesystem 100, thereby maximizing use of the air-cooled condenser system80.

In certain embodiments, additional heat transfer in conjunction with theair-cooled condenser system 80 may be achieved by utilizing a condenserspray system 120 as is illustrated. in FIGS. 2A and 2B. Condenser spraysystem 120 generally includes a basin 122 positioned below air-cooledheat exchanger bundle 91 and a heat exchanger sprayer manifold 124 influid communication with the basin 122. A pump 123 is utilized to pump aliquid, such as water, from the basin 122 to the manifold 124. Themanifold is provided with a plurality of openings or nozzles 125 and ispositioned above heat exchanger bundles 91 so that bundles 91 may besprayed with water to enhance heat transfer from the second workingfluid. In certain embodiments, bundles 91 are generally comprised of oneor more coils 92 through which the refrigerant flows. Those skilled inthe art will appreciate that such a system is particularly effectivewhere bundles 91 are arranged to be substantially horizontal and the fan88 is placed above the bundles 91 to induce air flow across the bundlesin a substantially vertical direction of airflow.

In another preferred embodiment, a drain pan having a cooling coilcondensate drain 128 is position below the chilled water cooling coils32 of turbine inlet cooling system 30 and is disposed to collectcondensate water from coils 32. Via cooling coil condensate drain 128.the drain pan is fluidly connected to condenser spray basin 122,permitting use of the condensate water as part of condenser spray system120 so as to minimize or eliminate the amount of basin makeup water 126required from external water sources.

In one embodiment of the invention, the turbine inlet air temperature(often called the T2 temperature) can be precisely adjusted to a higheror lower temperature to allow the overall output of the air-cooled,combined cycle plant to be maintained at a constant MW output regardlessof the ambient temperature. This is especially true if thermal energystorage is provided along with the TIC system. In addition tomaintaining a fixed MW output regardless of ambient temperature, theoutput can also be varied up or down by varying the T2 turbine inlettemperature, which can add the ability for the combined cycle plant tobe used for voltage regulation grid support with a very fast responsetime. The ability to regulate output in this manner is becomingincreasingly important as more intermittent, non-firm renewable powergeneration is added to the grid which will require fast response“firming” power to make up the shortfalls or excesses caused by thefluctuating renewables. Thus, in one embodiment of the invention, theturbine inlet air temperature T2 may be varied to maintain the overallcombined cycle plant output at a desired power output level. A preferredmethod for varying the T2 temperature is by varying the flow of chilledwater through the cooling coil 35 using either a flow control valve orpreferably by varying the speed of a secondary pump 116 disposed to pumpchilled water through the cooling coil 35.

As described above, in one embodiment of the invention, the air-cooledcondenser may serve a dual function, as a heat rejection system for boththe ORC system and the TIC system. Specifically, one advantage of usingan air-cooled, refrigerant condenser as described in certain embodimentsinstead of a traditional air-cooled, steam condenser is that theair-cooled, refrigerant condenser permits the use of the air-cooledcondenser of the system for dual purposes, depending on the time of dayand whether the combined cycle plant is running or not. When thecombined cycle plant is operating to generate power, the air-cooledcondenser would be dedicated for use as the heat rejection device forthe thermal bottoming cycle as described above. However, when thecombined cycle plant is not generating power (usually at night, forinstance), then the air-cooled condenser of the invention can beutilized as the heat rejection for the turbine inlet cooling system tothe extent a thermal storage system is employed. In certain embodimentsof the invention, this is an important feature since turbine inletcooling with TES system would ideally operate at night when the cost ofpower is less, and as such, it would utilize the low cost grid power todrive the turbine inlet cooling chiller compressor to provide chilledwater which would be stored in the TES tank for later use when thecombined cycle is operating to generate power. The heat that isextracted from the stored chilled water would then be rejected to therefrigerant working fluid and then to the air-cooled condenser. Duringthe day, when power prices are higher, the combined cycle plant wouldagain begin generating power and the air-cooled condenser would then beswitched back to the ORC bottoming cycle while the turbine inlet coolingsystem would run entirely off the stored TES chilled water. Since theturbine inlet cooling chiller system would no longer be operable withoutthe use of the air-cooled condensers, having switched back to a heatsink for power generation rather than as a heat sink for refrigeration,the TES system must be utilized. Although not necessary, preferably thedual purpose air-cooled condenser could utilize the same working fluidfor both the separate working fluid for the ORC bottoming cycle and alsoas the refrigerant for the chiller system of the turbine inlet coolingsystem. In one preferred embodiment, such working fluid could be eitherammonia or R134a, although other fluids may also be utilized. Notably,the heat rejection required for the ORC bottoming cycle is much largerthan that required for the turbine inlet cooling system (on the order of7 to 10 times larger) so only a portion of the total ORC air-cooledcondensers would be needed to be shared with the turbine inlet coolingrefrigeration system. Of course, in an alternative embodiment, separateair-cooled condensers may be utilized for each of the ORC system and theturbine inlet cooling system which is anticipated to be the preferredembodiment for most projects.

Furthermore, while a preferred horizontal bundle, air-cooled condenserhas been described herein for use with certain embodiments of theinvention combining a steam turbine topping system with an organicworking fluid bottoming system, those of ordinary skill in the art willappreciate that other embodiments of the invention which employ turbineinlet cooling with a steam turbine topping system and an organic workingfluid bottoming system may be utilized with any configuration ofair-cooled condenser.

In summary, the system of the invention provides a method foreliminating the use of water for condensing steam from a steam bottomingcycle from a gas turbine combined cycle power plant by utilizing heatfrom the gas turbine in two separate working fluid circuits that eachuse a different working fluid. The high temperature first circuit willuse the traditional water working fluid such that the steam which isproduced from the exhaust heat of a gas turbine is first introduced intoa backpressure steam turbine at a higher first steam pressure and thenextracted from the steam turbine at a lower second steam pressure whichis still above atmospheric pressure, and condensing said second steampressure by heat exchange in a steam condenser/ORC vaporizer heatexchanger. This heat exchanger use the ORC working fluid of a secondfluid circuit as the condensing medium (instead of water or air as inthe prior art). Condensed steam, which is condensed to a liquid in thevaporizer heat exchanger will be pumped back to the HRSG to repeat thesteam cycle. Meanwhile the heat extracted from the condensing of thesteam will be transferred to the separate ORC working fluid. This ORCworking fluid is selected to have a lower boiling point than that ofwater, thereby permitting the ORC working fluid to be used foradditional work (rather than rejecting this heat directly to anair-cooled condenser as is the prior art). The heat from the condensingsteam will vaporize the ORC working fluid which will then be used todrive an expander in the second circuit to produce power. The exhaustfrom the expander of the second circuit will be condensed in anair-cooled condenser heat exchanger and the condensed liquid will thenbe pumped back to the vaporizer heat exchanger. The inlet air of the gasturbine will be cooled, at least some of the time, utilizing a turbineinlet cooling system. The turbine inlet cooling system utilizes acirculating chilled liquid to regain some of the power capacity whichmay be otherwise lost during operation of both the gas turbine and thesteam turbine cycle during periods of high ambient temperature. In onepreferred embodiment the steam is extracted from the steam turbine at apressure in the range of approximately 2 psig to 35 psig. The air-cooledcondenser includes an air-cooled heat exchanger system that is fluidlycoupled to the expander of the second circuit and operable to releaseheat from the second circuit working fluid, i.e., the ORC working fluid.Preferably the air-cooled heat exchanger includes one or more coils,arranged in elongated bundles and supported so as to be substantiallyhorizontal with a substantially horizontal induced draft fan mountedabove the bundle(s).

In certain embodiments, the turbine inlet cooling system is a separatecircuit that utilizes chilled fluid flowing through one or more coolingcoils mounted in the inlet air stream of the gas turbine. The chilledfluid is preferably water or primarily water, and the chilled fluid iscooled through the use of one or more mechanical chillers. The chilledwater may be at least partially stored in a chilled water thermalstorage tank having an upper diffuser for supply and return of warmerwater and a lower diffuser for supply and return of colder water. Someor all of the cooling turbine inlet cooling system may be supplied bythe stored chilled water to reduce or eliminate the need for thechillers to operate during peak power periods.

During certain peak temperature periods, the condensate which isproduced at the cooling coils from cooling the inlet turbine air to atemperature below the dew point when the gas turbine inlet coolingsystem is active may be collected and used to provide evaporativecooling to the air-cooled condensers. In one embodiment, the condensatemay be sprayed directly on the air-cooled condenser bundles to providedirect contact between the condensate water and the condenser heatexchangers. A basin may be deployed below the air cooled heat exchangerbundles to collect excess water which remains unevaporated, andthereafter, the water may be recirculated in the spraying system. In thealternative, or in addition to this cooling water, water for thespraying system may be supplied from other sources, such as city wateror ground water or river water to supplement the condensate water usedfor spraying the air-cooled heat exchanger. An additional benefit of theforegoing, is that a fresh water rinse cycle may be provided just priorto the conclusion of the spraying cycle to rinse the condenser coil ofany remaining mineral residues which might be entrained in the recycledspray water.

Although the steam/organic rankine (“ST/ORC”) hybrid cycle system of theinvention may be applied to all condensing steam cycle plants, it ismost useful for gas turbine combined cycles and for direct-fired (coal)plants. In another embodiment of the invention, rather than utilizingwaste heat from a combustion turbine as the heat source for the ST/ORChybrid cycle system of the invention, heat from other sources may beutilized. In certain embodiments, for example, waste heat may berecovered from industrial processes, such as for example, cement plants,steel plants, kilns, or other manufacturing plants. Of course, in suchcases, the need for turbine inlet cooling is eliminated with theelimination of the combustion turbine as the heat source. Thus, in oneembodiment of the invention, an industrial plant comprises a source ofwaste heat from an industrial process; a steam turbine topping systemdisposed to utilize exhaust heat from the waste heat source to heat afirst working fluid; an Organic Rankine Cycle (ORC) bottoming systemdisposed to utilize exhaust steam from the steam turbine topping systemto heat a second working fluid; and an air-cooled heat exchangerdisposed to cool gaseous second working fluid from the ORC bottomingsystem.

The system of the invention has numerous advantages over the prior artsystems. First, the invention eliminates the use of wet cooling towersas well as air-cooled steam condensers by incorporating an ORC bottomingcycle, which volume flow is approximately 1/122 that of steam, thusresulting in substantial reduction in the installed cost of theair-cooled condenser for a power plant steam bottoming cycle. Further,it is estimated that air cooling for a typical 500 MW combined cycleplant could save approximately 1100 gpm which, on an annual basis, savesabout 550 million gallons. Moreover, cooling the gas turbine exhaust,which is not beneficial in steam plant, and removing the deaerator, willlikely allow the ST/ORC power plant of the invention to generate thesame output as an equivalent sized air-cooled condensing steam plant ofthe prior art operating under the same conditions. Additionally, byintegration of a turbine inlet cooling system and TES system, the plantoutput during high ambient temperature summer operation can beincreased, more than offsetting any performance loss associated with aircooling in hot weather. The high efficiency air-cooled condenser alsoreduces fan losses and operation and maintenance costs below that ofcurrent prior art designs. The ST/ORC bottoming cycle also reduces theamount of live steam needed for the deaerator, reduces vacuum pumppower, and chemical treatment of feed water, all resulting from totalelimination of vacuum stages of the steam turbine. Finally, the ST/ORCsystem provides a better match between gas turbine exhaust gas coolingand ST/ORC heating curves, thus reducing efficiency losses between thecurves.

An exemplary methodology of the present invention provides a method forproducing power from a combined cycle power plant, said methodcomprising the steps of cooling inlet air to a combustion turbine, thecooled inlet air having a first temperature; utilizing a steam turbinetopping cycle in association with the combustion turbine to generatepower; utilizing an ORC bottoming cycle in association with the steamturbine topping cycle to generate power; and utilizing an air-cooledcondenser to remove heat from the ORC bottoming cycle.

While certain features and embodiments of the disclosure have beendescribed in detail herein, it will be readily understood that thedisclosure encompasses all modifications and enhancements within thescope and spirit of the following claims. Furthermore, no limitationsare intended in the details of construction or design herein shown,other than as described in the claims below. Moreover, those skilled inthe art will appreciate that description of various components as beingoriented vertically or horizontally are not intended as limitations, butare provided for the convenience of describing the disclosure.

It is therefore evident that the particular illustrative embodimentsdisclosed above may be altered or modified and all such variations areconsidered within the scope and spirit of the present disclosure. Also,the terms in the claims have their plain, ordinary meaning unlessotherwise explicitly and clearly defined herein.

What is claimed is:
 1. A method for producing power from a power plant,the method comprising: providing a combustion turbine to generateexhaust heat; cooling air entering the combustion turbine; utilizing theexhaust heat from the combustion turbine to vaporize a first workingfluid; driving a first steam turbine with the vaporized first workingfluid; utilizing exhaust heat from the first turbine to vaporize anorganic working fluid; driving an organic working fluid expander withthe vaporized organic working fluid; utilizing an air-cooled condenserto cool exhaust from the organic working fluid expander; and vaporizinga working fluid in a chiller to chill water; utilizing the chilled waterto cool the cooling air entering the combustion turbine; directing thevaporized working fluid from the chiller through the air-cooled heatexchanger to cool the vaporized working fluid, and thereafter, directingthe cooled working fluid back to the chiller.
 2. A method for producingpower from a combined cycle power plant, the method comprising:providing a combustion turbine to generate exhaust heat; cooling inletair entering the combustion turbine; utilizing the exhaust heat from thecombustion turbine to vaporize a first working fluid; driving a steamturbine with the vaporized first working fluid; utilizing exhaust steamfrom the steam turbine to vaporize a second working fluid; driving asecond working fluid expander with the vaporized second working fluid;utilizing an air-cooled heat exchanger to cool exhaust from the secondworking fluid expander; and evaporating a working fluid in a chiller tochill water passing through the chiller, utilizing the chilled water tocool inlet air entering the combustion turbine; and utilizing theair-cooled heat exchanger to cool the evaporated working fluid.
 3. Amethod for producing power from a combined cycle power plant, the methodcomprising: providing a combustion turbine to generate exhaust heat;cooling inlet air entering the combustion turbine by passing the inletair across coils in which chilled water is disposed; utilizing theexhaust heat from the combustion turbine to vaporize a first workingfluid; driving a steam turbine with the vaporized first working fluid;utilizing exhaust steam from the steam turbine to vaporize a secondworking fluid; driving a second working fluid expander with thevaporized second working fluid; chilling the water in the cooling coilsby passing water through a chiller; evaporating a refrigerant in thechiller in order to chill the water passing therethrough; and utilizingan air-cooled heat exchanger to both i) cool exhaust from the secondworking fluid expander and ii) cool refrigerant entering the chiller.